Mining and Explosives Solutions

Ikhwezi Colliery Blast Audit

Site: Ikhwezi, Kliprand

Prepared by S.S. Mahlangu

Reviewed by. J. Botha

Date: 25/04/2024
Table of Contents
Table of Contents ......................................................................................................................... 2
1.Introduction ............................................................................................................................... 3
2.Planned Blast Parameters ............................................................................................................. 3
3.On Bench Observations ................................................................................................................ 3
4.Pre-blast Photographs.................................................................................................................. 4
5.Hole Depth Quality ...................................................................................................................... 5
6.Drill Pattern Compliance............................................................................................................... 6
7.Explosive Density Compliance ....................................................................................................... 7
8.Stemming Length Compliance ....................................................................................................... 8
9.Post Blast Photographs ................................................................................................................ 9
10.Ground Vibration and Airblast Results ........................................................................................ 11
11.Conclusion and Recommendations ............................................................................................ 13
12.Annexures .............................................................................................................................. 14
 1. Introduction
BME’s operations technical visited Ikhwezi colliery, Kliprand section During the month of April 2024.
Activities conducted included a blast audit, and ground vibration and air blast monitoring. The audit
was conducted by focusing on key areas such as bench preparation, drilling compliance, priming,
loading, density and stemming control. The focus of airblast & ground vibration monitoring is to
establish if blast induced airblast and ground vibration levels are within allowable limits at surrounding
buildings, and to ensure that employees and the surrounding community are safe from any potential
harm.

2. Planned Blast Parameters

The following Table 1 represents the communicated planned blast parameters.

Table 1: This table represents the planned blast parameters.

Parameters
Initiation Type Pyrotechnics
Explosive type INNOVEX™100
Charge mass/meter (kg/m) 25.7
Critical Diameter (mm) 64
3
Average in-hole density (g/cm ) 1.2
Cup or Collar density(g/cm3) 1.0
Stemming Length (m) 3.5
Stemming Type Drill Cuttings
Average Hole Depth (m) 23.3
Planned Hole Diameter (mm) 165
Burden (m) 5
Spacing (m) 6
Average hole Powder Factor 0.73
(kg/m3)
Initiation System Type 35.4m/17ms/350ms EZ dets
Booster size (g) & Type 800g (Trojan)

3. On Bench Observations
The following observations were noted by the technical representative:

 The block consisted of 9 lines, with 11 holes in a row. The measured actual depths averaged at
23.3m.
 The bench floor was relatively clean, even and level.
 The effective burden from the point of initiation was measured to be equivalent to 4.8m.
  Random crest burden dimensions measurements averaged at 6.4m.
 Some overcharged blast holes were experienced, treated accordingly using the relevant
suction pipe and the initial twine length was increased from 5.5m to 6m, showing a proactive
approach to stemming control.
 After the standard sensitization period, the blast holes were stemmed using drill cuttings.
 A pyrotechnic initiation system was used to fire the shot.
 The total INNOVEXTM100 bulk emulsion charged in the entire block equated to 53175kg which
is equivalent to 53.2tons.

4. Pre-blast Photographs

Figure 1: This photograph shows the suction process of some overcharged blast holes.

Figure 2: This photograph shows the charging and twinning processes and other bench preparation processes.
Figure 3: This is the image of the two free faces and the point of intersection of the two free faces captured from the
bottom.

5. Hole Depth Quality

The communication indicated that the block had been drilled months prior. Initially, the actual depths
were measured and averaged at 31 meters. Before charging with explosives, the actual hole depths
were remeasured and averaged at 23.3 meters. This reveals that despite the drilled holes being
plugged with sandbags, the level of backfilling was significant due to the extended period before
charging.

The following Figure 4 is the chart representing the measured actual hole depths against the average
hole depths.

Figure 4: Chart of the measured actual hole depths against the calculated actual hole average depth.
 6. Drill Pattern Compliance
Ten burden and spacing distances were randomly selected and measured for actual distances,
correlating them with planned burden and spacing distances. Among the selected samples, 90% were
compliant, while 10% were non-compliant. The measured actual burden distance averaged at 5.3
meters, and the measured spacing distance averaged at 6.1 meters.

Figure 5 illustrates the relationship between actual and planned burden and spacing, while Figure 6
depicts the compliance percentage pie chart. The acceptable tolerance was set at 10% of the planned
pattern.

Figure 5: Chart representing measured actual burden and spacing distances compared to planned burden and
spacing distances.

Figure 6: Is a Pie-chart revealing the compliance percentage achieved.

 7. Explosive Density Compliance
Ten samples of INNOVEXTM100 bulk emulsion explosive cups were selected from the blast bench and
measured for their actual mass. The actual densities were then calculated and compared to the
planned cup or collar density, resulting in a compliance grade of 83%. The measured densities ranged
from a minimum of 0.93 g/cc to a maximum of 1.05 g/cc, with an average of 0.99 g/cc, which aligns
with the desired target on average.

Figure 8 illustrates the comparison between the actual cup densities and the planned density, while
Figure 7 presents the compliance pie chart.

Figure 7: Is a Pie-chart revealing the compliance percentage achieved.

Figure 8: Line chart represents actual densities correlated to the planned density.
 8. Stemming Length Compliance
Twenty-two blast holes were randomly selected, and after the sensitization period, their actual
stemming lengths were measured and compared to the planned stemming length. Eighty-two percent
of the selected blast holes were within the acceptable limit, while 18% were outside the acceptable
limit. The acceptable tolerance was set at 10% of the planned final stemming. Figure 9 illustrates the
stemming length measurements, while Figure 10 depicts the compliance grade pie chart.

Figure 9: Chart representing actual stemming lengths in comparison to planned stemming length.

Figure 10: Pie-chart revealing the compliance percentage achieved.

 9. Post Blast Photographs

Figure 11: Photograph of the entire blast captured from the view area.

Figure 12: Photograph of fragmentation captured in a close range.

Figure 13: Photograph showing a blast induced crack extending into the adjacent block.

Figure 14: Photograph of the cross-sectional view of the crack showing a minor shift in the area highlighted in yellow.
 10. Ground Vibration and Airblast Results
The focus on air blast and ground vibration monitoring is to establish whether the current air blast
and ground vibration levels are within allowable limits at the structures of concern according to the
USBM limit. The reason for conducting the measurements is to ensure that all employees and the
surrounding community are safe from any potential harm.

Air blast and ground vibration limits

While many countries lack formalized limits for vibration, the limits set by the US Bureau of Mines
(USBM) are commonly adopted in South Africa. The limiting curve depicted in Figure 15 represents
the threshold for cosmetic damage to a house. Ground vibration amplitudes vary with frequency, with
higher frequencies permitting higher peak amplitudes. Most modern blasting seismographs present
vibration data in accordance with the USBM limiting criterion.

Generally, at lower frequencies, ground vibration should not exceed 12.7 mm/s for houses of lesser
construction quality and 25 mm/s for well-built buildings. Traditional mud houses typically have a limit
of 6 mm/s. According to the USBM, the safe limit for air blast is 134 dB as being a maximum for any
inconvenience.

Figure 15: USBM curve that is generally used in South Africa.

The environmental conservation of blasting is of paramount significance to protect structures of
concern. Therefore, most mining companies and blasting contractors utilize seismographs to regularly
monitor blast induced PPV’s and airblast. PPV, noise and airblast can be summarized as follows:

 PPV (Peak Particle Velocity): Is the amplitude (maximum or peak) speed of ground
vibrations produced by a rock particle at a point. Ground vibrations is function of blast
timing and explosive charge per hole.
 Frequency: The rate at which something occurs over a particular period, F = 1/T, it is
measured in Hz (Hertz).
 Noise or Sound: Air vibrations audible to human ear at frequencies above 20Hz.
 Airblast or air concussion: Airblast is an inaudible vibration through air, it consists of
frequencies less than 20Hz, it feels like a gust of wind to the observer.
Airblast is a function of stemming quality, stemming quantity, blast timing and front row
burdens, atmospheric conditions etc.

To completely measure the motion of a particle on the surface, three perpendicular (at right angle to
each other) components of motion, namely longitudinal/radial PPV, Transverse PPV and Vertical PPV:

 Longitudinal (Radial) is oriented along a horizontal radius towards the blast (back and forth
particle motion from the blast to the monitoring point).
 Transverse(T) component is the right angles to the longitudinal direction (sideways motion of
the particle).
 Vertical(V) is at right angles to both the radial and transverse components (up and down
motion of the particle).

A single seismograph was employed to monitor blast-induced vibration and airblast in the neighboring
community. Table 2 presents the technical specifications of the seismograph and the authorized
monitoring locations. Table 3 provides a summary of the measured results, and the event summary
obtained from the seismograph is attached in the appendices.

Table 2: Seismographs technical data and seismograph monitoring points.

Distance Trigger Levels Triggered
Serial Calibration Authorized from blast
PPV Air Blast
No. Date (m)
Location Yes No
(mm/s) (dB)

20138 28/03/2024 Opposite Tuck Shop ±500 1.0160 125.0 X

Table 3: Seismograph triggered results.

Radial Vertical Transverse Air blast
Serial
PPV Freq PPV Freq PPV Freq dB
No.
(mm/s) (Hz) (mm/s) (Hz) (mm/s) (Hz)

20138 4.318 128.00 3.556 102.40 2.921 102.40 115

 11. Conclusion and Recommendations
The blast reaped good fragmentation which facilitated high loading and hauling rates. A major crack
which extended to the adjacent block was encountered after the blast. The monitored ground
vibrations and airblast were within the set limits as per the USBM criterion.

The following can be recommended can be implemented to optimize results going forward:

 Limit the excess handover time from drilling to charging to combat the issue of high backfill
levels.
 Implementing a 45-degree cut-off pre-split at the end of blocks during drilling and blasting
operations can effectively reduce the risk of back break into adjacent blocks.
 Converting from pyrotechnics to electronics for more controlled blast; prevent crowding
and/or overlapping and/or off sequence firing and for single hole firing, to accurately control
ground vibration and air blast.
 Using graded aggregates which is sized 10% to 15% the hole diameter as a stemming material
will assist with energy retention, optimizing fragmentation and reducing air blast levels.
 Another additional measure to consistently maintaining airblast levels within the USBM limits
is to avoid blasting if the following atmospheric conditions are prevailing:
 Cloud cover of more than 21%
 Wind blowing towards the community and
 At a velocity of more than 15km/h.
 12. Annexures
The following annexure A represents the measured actual hole depths compared to average depth.

Block Hole Number Average Hole Measured

Depth (m) Hole Depth
(m)

Kliprand OB Spot Check 1 23.3 24.8

Kliprand OB Spot Check 2 23.3 22

Kliprand OB Spot Check 3 23.3 22.9

Kliprand OB Spot Check 4 23.3 23.1

Kliprand OB Spot Check 5 23.3 24.1

Kliprand OB Spot Check 6 23.3 23.1

Kliprand OB Spot Check 7 23.3 24.1

Kliprand OB Spot Check 8 23.3 24.3

Kliprand OB Spot Check 9 23.3 23.2

Kliprand OB Spot Check 10 23.3 23

Kliprand OB Spot Check 11 23.3 22.4

Kliprand OB Spot Check 12 23.3 24

Kliprand OB Spot Check 13 23.3 25.6

Kliprand OB Spot Check 14 23.3 24.8

Kliprand OB Spot Check 15 23.3 24.3

Kliprand OB Spot Check 16 23.3 23.0

Kliprand OB Spot Check 17 23.3 23.4

Kliprand OB Spot Check 18 23.3 24.1

Kliprand OB Spot Check 19 23.3 25.0

Kliprand OB Spot Check 20 23.3 24.0

Kliprand OB Spot Check 21 23.3 23.8

Kliprand OB Spot Check 22 23.3 19.7

 Kliprand OB Spot Check 23 23.3 22.2

Kliprand OB Spot Check 24 23.3 19.9

Kliprand OB Spot Check 25 23.3 23.1

Kliprand OB Spot Check 26 23.3 23.0

The following annexure B represents the measured actual pattern dimensions versus planned
pattern dimensions.

Hole No. Measured Burden (m) Measured Spacing (m)

Spot Check 1 4.8 5.7

Spot Check 2 5.2 5.9

Spot Check 3 6.1 6.1

Spot Check 4 5.9 6.4

Spot Check 5 5.4 6.1

Spot Check 6 5.1 6.0

Spot Check 7 5.1 6.2

Spot Check 8 5.1 6.0

Spot Check 9 5.2 6.2

Spot Check 10 5.1 6.1

The following annexure C is the table representing actual against planned densities.

Block Hole Number Planned final cup Measured

density (g/cm3) cup density
(g/cm3)

Kliprand OB Spot Check 1 1.00 0.95

Kliprand OB Spot Check 2 1.00 1.03

Kliprand OB Spot Check 3 1.00 0.95

Kliprand OB Spot Check 4 1.00 0.93

 Kliprand OB Spot Check 5 1.00 1.00

Kliprand OB Spot Check 6 1.00 0.98

Kliprand OB Spot Check 7 1.00 0.95

Kliprand OB Spot Check 8 1.00 1.03

Kliprand OB Spot Check 9 1.00 1.05

Kliprand OB Spot Check 10 1.00 1.05

Kliprand OB Spot Check 11 1.00 0.94

Kliprand OB Spot Check 12 1.00 1.04

The following annexure D is the table representing actual stemming lengths correlated to planned
stemming length.

Block No Hole Number Planned Stemming Measured

Length (m) Stemming
Length (m)

Kliprand OB Spot Check 1 3.5 3.4

Kliprand OB Spot Check 2 3.5 3.6

Kliprand OB Spot Check 3 3.5 4.2

Kliprand OB Spot Check 4 3.5 3.5

Kliprand OB Spot Check 5 3.5 3.0

Kliprand OB Spot Check 6 3.5 3.5

Kliprand OB Spot Check 7 3.5 3.8

Kliprand OB Spot Check 8 3.5 3.2

Kliprand OB Spot Check 9 3.5 3.7

Kliprand OB Spot Check 10 3.5 4.1

Kliprand OB Spot Check 11 3.5 3.6

Kliprand OB Spot Check 12 3.5 2.8

Kliprand OB Spot Check 13 3.5 3.5

 Kliprand OB Spot Check 14 3.5 3.1

Kliprand OB Spot Check 15 3.5 3.3

Kliprand OB Spot Check 16 3.5 2.9

Kliprand OB Spot Check 17 3.5 3.5

Kliprand OB Spot Check 18 3.5 3.4

Kliprand OB Spot Check 19 3.5 3.2

Kliprand OB Spot Check 20 3.5 3.4

Kliprand OB Spot Check 21 3.5 3.8

Kliprand OB Spot Check 22 3.5 3.5

The following Annexure E and F shows the recommended ground vibration and airblast event
summary.
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